Method for producing vapor generation unit for non-combustible flavor inhaler

Abstract

A method for producing a vapor generation unit, which is for generating a vapor by heating a liquid and is to be used in a non-combustible flavor inhaler, includes: a support feeding step of feeding a wick support to a production line for the vapor generation unit; a wick feeding step of, after the support feeding step, feeding a wick toward the wick support and disposing the same on the wick support; a holder feeding step of, after the wick feeding step, feeding a wick holder toward the wick support and assembling the same on the wick support; and a heater feeding step of, after the holder feeding step, feeding a heater toward the wick holder and assembling the same on the wick support.

The invention claimed is: 
     
       1. A method for producing a vapor generation unit for a non-combustible flavor inhaler, the vapor generation unit heating a liquid to generate vapor, the vapor generation unit including
 a wick that retains the liquid, 
 a wick support onto which the wick is placed, 
 a wick holder that, when mounted to the wick support, sandwiches the wick between the wick holder and the wick support and defines an exposed face through which the wick is exposed, and 
 a heater having a heater element, the heater element being brought into contact with the exposed face when the heater is mounted to the wick support, 
 the method comprising: 
 a support feeding step of feeding the wick support to a production line for the vapor generation unit; 
 a wick feeding step of, after the support feeding step, feeding the wick toward the wick support to place the wick onto the wick support; 
 a holder feeding step of, after the wick feeding step, feeding the wick holder toward the wick support to mount the wick holder to the wick support; and 
 a heater feeding step of, after the holder feeding step, feeding the heater toward the wick holder to mount the heater to the wick support. 
 
     
     
       2. The method according to  claim 1  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the wick support includes a support part, the support part having a liquid introduction opening for introducing the liquid to the wick, and a curved support face defining an opening edge of the liquid introduction opening, and 
 wherein the wick feeding step incudes
 a wicking-material cutting process of cutting a wicking material into a size that fits the support part, the wicking material being a material of the wick, 
 a wicking-material shaping process of shaping the wicking material cut in the wicking-material cutting process to impart a curved face to the wicking material, the curved face having a curvature that conforms to the support face, and 
 a wick inspection process of inspecting a profile of the wick formed in the wicking-material shaping process. 
 
 
     
     
       3. The method according to  claim 2  for producing a vapor generation unit for a non-combustible flavor inhaler, further comprising a wick-position inspection step of, after the wick feeding step, inspecting a position of the wick placed on the wick support. 
     
     
       4. The method according to  claim 3  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the wick-position inspection step includes
 a liquid-introduction-opening inspection of inspecting whether the wick covers the liquid introduction opening, and 
 a support-face inspection of inspecting whether an outer peripheral edge of the wick is aligned with the support face. 
 
 
     
     
       5. The method according to  claim 4  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the wick holder includes a holder part, the holder part having an exposed opening and a holder face, the exposed opening defining the exposed face when the wick holder is mounted to the wick support, the holder face defining an opening edge of the exposed opening, the holder face being curved to allow the holder face to sandwich the outer peripheral edge of the wick between the holder face and the support face, and 
 wherein the holder feeding step includes a holder pressing process of, to define the exposed face, pressing the holder face against the support face with a predetermined holder-pressing force. 
 
     
     
       6. The method according to  claim 5  for producing a vapor generation unit for a non-combustible flavor inhaler, wherein the holder-pressing force has a magnitude sufficient to prevent the liquid retained in the wick from leaking through the outer peripheral edge of the wick sandwiched between the support face and the holder face. 
     
     
       7. The method according to  claim 6  for producing a vapor generation unit for a non-combustible flavor inhaler, further comprising an exposed-face inspection step of, after the holder feeding step, inspecting a profile of the exposed face. 
     
     
       8. The method according to  claim 7  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the exposed-face inspection step includes
 an exposed-face inspection of inspecting a condition of the exposed face, 
 an exposed-face curvature inspection of inspecting a radius of curvature of the exposed face, and 
 an exposed-face position inspection of inspecting a position of the exposed face in the wick support. 
 
 
     
     
       9. The method according to  claim 8  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the heater includes the heater element, and a pair of electrodes that generate heat upon supply of power, and 
 wherein the heater feeding step includes
 an element shaping process of shaping the heater element into a shape that conforms to the exposed face, 
 an element securing process of bringing opposite ends of the heater element shaped in the element shaping process into contact with the pair of electrodes to secure the heater element onto the pair of electrodes, and 
 a heater inspection process of inspecting a profile of the heater element secured in the element securing process. 
 
 
     
     
       10. The method according to  claim 9  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the heater inspection process includes
 an element-curvature inspection of inspecting a radius of curvature of the heater element, 
 an element-length inspection of inspecting whether a heat-generating region of the heater element has a predetermined length, and 
 an element-position inspection of inspecting a position of the heater element in the heater, and 
 a resistance inspection of inspecting an electrical resistance provided by the heater element when power is supplied to the pair of electrodes. 
 
 
     
     
       11. The method according to  claim 10  for producing a vapor generation unit for a non-combustible flavor inhaler, wherein the heater feeding step further includes an element-pressing process of, in mounting the heater to the wick support, pressing the heater element with a predetermined pressing force against the exposed face into contact with the exposed face. 
     
     
       12. The method according to  claim 11  for producing a vapor generation unit for a non-combustible flavor inhaler, wherein the element-pressing force has a magnitude that allows an entirety of the heat-generating region of the heater element to come into contact with the exposed face, and prevents a break from occurring in the heater element. 
     
     
       13. The method according to  claim 12  for producing a vapor generation unit for a non-combustible flavor inhaler, further comprising
 an assembly inspection step of, after the heater feeding step, inspecting a state of assembly of the vapor generation unit whose assembly is completed, 
 wherein the assembly inspection step includes an element-contact inspection process of inspecting a state of contact between the exposed face and the heater element. 
 
     
     
       14. The method according to  claim 13  for producing a vapor generation unit for a non-combustible flavor inhaler,
 wherein the element-contact inspection process includes
 an assembly error inspection of inspecting a state of contact between the heater element and the wick based on a height of the vapor generation unit in a direction in which the heater element and the wick contact each other, and 
 a post-assembly resistance inspection of inspecting a state of contact between the heater element and the wick based on an electrical resistance, the electrical resistance being an electrical resistance provided by the heater element when power is supplied to the pair of electrodes.